Furness Newburge Inc.

Versailles, KY, United States

Furness Newburge Inc.

Versailles, KY, United States
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Nieto-Delgado C.,Pennsylvania State University | Cannon F.S.,Pennsylvania State University | Paulsen P.D.,Furness Newburge Inc. | Furness J.C.,Furness Newburge Inc. | And 2 more authors.
Fuel | Year: 2014

The authors have developed bindered anthracite briquettes that can replace conventional coke as a fuel in foundry cupolas. The anthracite briquettes included fine anthracite grains that were bindered together with collagen, lignin and silicon. These binders gave the briquettes high mechanical strength through the full spectrum of temperatures encountered in a foundry cupola furnace - from ambient temperature up to 1550 C. The bindered anthracite briquettes offered the same structural strength and fuel content as has conventional foundry grade coke. The conventional coking process involves pyrolyzing coal at 1000 C for a day; and this consumes about 15% of the raw coal's energy, while releasing volatile organic air pollutants. In contrast, the briquetting process consumes scant energy, without releasing pollutants. During two full-scale demonstrations that each employed 4 tons of these briquettes, the anthracite briquettes performed similarly to the foundry grade coke, while the briquettes replaced up to 25% of the coke. During briquette replacements, the cupola temperatures, off-gas CO/CO2 proportions, tuyere back-pressures, and metal-to-fuel ratios were maintained or improved. The iron castings produced during this briquette replacement were of the same high quality and composition as when mere coke was used; and these iron castings were sold. Observations through the tuyere windows - where oxygen-enriched air was lanced into the bottom of the cupola - showed that these anthracite briquettes reached the cupola's melting zone while maintaining their physical integrity. Once these briquettes reached the level of the tuyere windows, they exhibited faster burning in the oxygen-enriched air than did conventional coke. © 2013 Elsevier Ltd. All rights reserved.


Trademark
AlMare International LLC, J.B. DeVenne Inc., Entelechy Inc. and Furness Newburge Inc. | Date: 2011-08-09

Combined organic and inorganic molding compounds used in the manufacture of metallic castings.


Torielli R.M.,Pennsylvania State University | Cannon F.S.,Pennsylvania State University | Voigt R.C.,Pennsylvania State University | Considine T.J.,University of Wyoming | And 4 more authors.
International Journal of Metalcasting | Year: 2014

The authors and collaborators have devised innovative technologies that decrease foundry costs, pollution, materials use, and energy. These include: (a) applying advanced oxidation to green sand and haghouse dust to diminish clay, coal, sand, volatile organic compounds (VOCs), and costs; (b) replacing phenolic urethane core binders with collagen-alkali silicate binders to diminish VOCs; (c) replacing coke with anthracite fines held together with biomaterial to reduce energy and costs. It is proposed by the authors that if a foundry were to concurrently employ all these innovative technologies (with 50% anthracite bricks), it could potentially diminish overall costs by 6.6%, life cycle energy costs by 15%, VOC pollution by 57%, sand by 85%, clay and coal by 50%, and iron scrap by 9%. These computations are per full-scale operations for advanced oxidation; and R&D results for replacing binders and coke. This paper also notes that when electricity comes primarily from coal fired power plants, electric induction furnaces consumes more life cycle energy than do cupolas for melting iron. Copyright © 2014 American Foundry Society.


Fox J.T.,Lehigh University | Cannon F.S.,Pennsylvania State University | Brown N.R.,Pennsylvania State University | Huang H.,Lehigh University | Furness J.C.,Furness Newburge Inc.
International Journal of Adhesion and Adhesives | Year: 2012

Metalcasting within the United States aims to meet ever-more stringent environmental standards as new process technologies are developed. Conventional foundry core binders are responsible for up to 70% of a foundrys volatile organic compound (VOC) emissions. New core binder technologies are essential for environmental sustainability within foundries. Herein, conventional and novel foundry core binders were appraised using thermal gravimetric analysis (TGA), dynamic mechanical analysis (DMA), hot distortion testing (HDT), and (Pilot-scale) molten iron erosion tests. Inherently, these tests cannot replace full-scale casting trials to evaluate binder effectiveness, however, these tests were performed to more fully elucidate binder properties that might cause casting defects or other unwanted behaviors at high temperatures. During each of these lab protocols, the combination of collagen plus alkali silicate as binders exhibited properties that matched or exceeded those of conventional phenolic urethane. Also, in iron erosion testing, the collagen/alkali silicate binder exhibited the same low erosion as conventional phenolic urethane. In hot distortion testing, the collagenalkali silicate binder exhibited longer resistance to thermal bending, and comparable thermal flexibility to conventional phenolic urethane. © 2012 Published by Elsevier Ltd.


Fox J.T.,Lehigh University | Allen J.F.,Pennsylvania State University | Cannon F.S.,Pennsylvania State University | Cash C.C.,Pennsylvania State University | And 5 more authors.
International Journal of Metalcasting | Year: 2015

A novel core binder system has been devised that is comprised of hydrolyzed collagen and alkali silicates. Cores that employ this hybrid binder were tested in a full-scale demonstration at a partner foundry. Among the 244 iron castings manufactured at this facility while using these hybrid binders, none of the iron castings were rejected as scrap due to core-related defects. The core regions of these iron castings exhibited no deformation, veining, or erosion from molten iron exposure. Moreover, these hybrid silicate-collagen cores demonstrated satisfactory shakeout during full-scale demonstrations. This hydrolyzed collagen-alkali silicate binder yielded cores that achieved a higher tensile strength and less hot distortion than conventional phenolic urethane binders. Copyright © 2015 American Foundry Society.


Huang H.,Pennsylvania State University | Fox J.T.,Pennsylvania State University | Cannon F.S.,Pennsylvania State University | Komarneni S.,Pennsylvania State University | And 2 more authors.
Environmental Science and Technology | Year: 2011

An alternative fuel to replace foundry coke in cupolas was developed from waste anthracite fines. Waste anthracite fines were briquetted with Si-containing materials and treated in carbothermal (combination of heat and carbon) conditions that simulated the cupola preheat zone to form silicon carbide nanowires (SCNWs). SCNWs can provide hot crushing strengths, which are important in cupola operations. Lab-scale experiments confirmed that the redox level of the Si-source significantly affected the formation of SiC. With zerovalent silicon, SCNWs were formed within the anthracite pellets. Although amorphous Si (+4) plus anthracite formed SiC, these conditions did not transform the SiC into nanowires. Moreover, under the test conditions, SiC was not formed between crystallized Si (+4) and anthracite. In a full-scale demonstration, bricks made from anthracite fines and zerovalent silicon successfully replaced a part of the foundry coke in a full-scale cupola. In addition to saving in fuel cost, replacing coke by waste anthracite fines can reduce energy consumption and CO2 and other pollution associated with conventional coking. © 2011 American Chemical Society.


Patent
Furness Newburge Inc. | Date: 2015-03-23

A system including a supercharged pulse jet engine is disclosed for the separation of a processing fluid. The system may include a rotary valve for introducing pockets of compressed air into the combustion chamber of the engine. Conditions of combustion may be adjusted in order to create squared waves within the exhaust to aid in separation. The processing fluid may be introduced into the exhaust stream of the engine, which may vaporize the process fluid, allowing compounds dissolved or suspended to be separated therefrom. The system may include a heat recovery system for pretreating the process fluid to conserve energy. Additionally, one or more separation elements such as an auger, a conveyor, a dust collector, a cyclone, or the like may be used to collect compounds separated from the process fluid. A condenser may be used to collect the fluid portion of the process fluid after separation.


Trademark
Furness Newburge Inc. | Date: 2016-05-27

unit to remove contaminants and reduce pollution from air, water and solids for industrial and commercial use.

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